Fire and water resistant expansion and seismic joint system

ABSTRACT

A fire and water resistant expansion and seismic joint system has a cover plate; a spline attached to the cover plate along a first edge of the spline; and a core comprising a first core portion and a second core portion, each portion being located on an opposing face of the spline. The first core portion and the second core portion have a fire-retardant material infused therein. The spline depends from the cover plate in a one piece construction and extends into the core to a depth within the core, and is positioned in a gap between substantially coplanar substrates such that the cover plate overlies the gap. Each portion of the core is compressed between a respective face of the spline and a face of one of the coplanar substrates.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Continuation Application of U.S. patentapplication Ser. No. 13/729,980, filed on Dec. 28, 2012, now U.S. Pat.No. 8,813,450, issued on Aug. 26, 2014, which is a Continuation-in-Partapplication of and claims priority to U.S. patent application Ser. No.12/730,354, filed on Mar. 24, 2010, now U.S. Pat. No. 8,341,908, issuedon Jan. 1, 2013, which claims the benefit of U.S. Provisional PatentApplication No. 61/162,820, filed on Mar. 24, 2009, the contents of eachof which are incorporated herein by reference in their entireties andthe benefits of each are fully claimed.

TECHNICAL FIELD

The present invention relates generally to joint systems and, moreparticularly, to an expansion and seismic joint system that is fire andwater resistant for use in building and construction applications.

BACKGROUND

Building and construction applications in which materials such asconcrete, metal, and glass are used typically employ joint systems thataccommodate thermal expansion and/or seismic movement of the variousmaterials thereof. These joint systems may be positioned to extendthrough both the interior and exterior surfaces (e.g., walls, floors,and roofs) of a building or other structure. In the case of an exteriorjoint in an exterior wall, roof, or floor exposed to externalenvironmental conditions, the joint system may also, to some degree,resist the effects of such conditions. As such, most exterior joints aredesigned to resist the effects of water. In particular,vertically-oriented exterior joints are designed to resist water in theform of rain, snow, ice, or debris that is driven by wind.Horizontally-oriented joints are designed to resist water in the form ofrain, standing water, snow, ice, debris such as sand, and in somecircumstances several of these at the same time. Additionally, somehorizontal systems may be subjected to pedestrian and/or vehiculartraffic and are designed to withstand such traffic.

In the case of interior joints, water tightness aspects are less of anissue than they are in exterior joints, and so products are oftendesigned simply to accommodate building movement. However, interiorhorizontal joints may also be subject to pedestrian traffic and in somecases vehicular traffic as well. Particularly with regard to joints inhorizontal surfaces, cover plates can be fitted over the joints to allowfor the smooth movement of traffic over the joint and/or to protect thematerial of the joint from the effects of the weather.

It has been generally recognized that building joint systems aredeficient with respect to fire resistance. In some instances, movementas a result of building joint systems has been shown to create chimneyeffects which can have consequences with regard to fire containment.This often results in the subversion of fire resistive elements that maybe incorporated into the construction of a building. This problem isparticularly severe in large high-rise buildings, parking garages, andstadiums where fire may spread too rapidly to allow the structures to beevacuated.

Early designs for fire resistive joints included blocks of mineral woolor other inorganic materials of either monolithic or compositeconstructions. Field-applied liquid sealants were often used in thesejoints. In general, these designs were adequate for non-moving joints orcontrol joints where movements were very small. Where movements werelarger and the materials were significantly compressed during the normalthermal expansion cycles of the building structure, these designsgenerally did not function as intended. Indeed, many designs simplylacked the resilience or recovery characteristics for maintainingadequate coverage of the entire joint width throughout the normalthermal cycle (expansion and contraction) that buildings experience.Many of these designs were tested in accordance with accepted standardssuch as ASTM E-119, which provides for fire exposure testing of buildingcomponents under static conditions and does not take into account thedynamic nature of expansion joint systems. As described above, thisdynamic behavior can contribute to the compromise of the fire resistanceproperties of some building designs.

Underwriters Laboratories developed UL 2079, a further refinement ofASTM E-119, by adding a cycling regimen to the test. Additionally, UL2079 stipulates that the design be tested at the maximum joint size.This test is more reflective of real world conditions, and as such,architects and engineers have begun requesting expansion joint productsthat meet it. Many designs which pass ASTM E-119 without the cyclingregime do not pass UL 2079. This may be adequate, as stated above, fornon-moving building joints; however, most building expansion jointsystems are designed to accommodate some movement as a result of thermaleffects (e.g., expansion into the joint and contraction away from thejoint) or as a result of seismic movement.

Both expansion joints and fire resistive expansion joints typicallyaddress either the water tightness (waterproof or water resistance)aspects of the expansion joint system or the fire resistive nature ofthe expansion joint system, as described above, but not both.

Water tight expansion joints exist in many forms, but in general theyare constructed from materials designed to resist water penetrationduring the mechanical cycling caused by movement of the building due tothermal effects. These designs generally do not have fire resistantproperties in a sufficient fashion to meet even the lowest fire ratingstandards. Indeed, many waterproofing materials act as fuel for any firepresent, which can lead to a chimney effect that rapidly spreads firethroughout a building.

Conversely, many fire rated expansion joints are not sufficiently watertight to render them suitable for exterior applications. Many designsreliant upon mineral wool, ceramic materials and blankets, andintumescents, alone or in combination with each other, have compromisedfire resistance by coming into contact with water. Additionally, asnoted above, many fire rated designs cannot accommodate the mechanicalcycling due to thermal effects without compromising the fire resistance.

This has resulted in the installation of two systems for each expansionjoint where both a fire rating and water resistance is desired. In manycases, there simply is not sufficient room in the physical spaceoccupied by the expansion joint to accommodate both a fire rated systemand a system capable of providing waterproofing or water resistance. Ininstances where the physical accommodation can be made, the resultantinstallation involves two products, with each product involving its owncrew of trained installers. Care is exercised such that one installationdoes not compromise the other.

Many systems also employ on-site assembly to create a finished expansionjoint system. This is arguably another weakness, as an incorrectlyinstalled or constructed system may compromise fire and water resistanceproperties. In some cases, these fire resistant expansion joint systemsdo not employ cover plates and are instead invasively anchored to theconcrete substrate. Over time, the points at which such systems areanchored are subject to cracking and ultimately spalling, which maysubvert the effectiveness of the fire resistance by simply allowing thefire to go around the fire resistant elements of the system. Withoutcover plates over the joints, fire in these cases would not be containedwithin the joints.

Also, many expansion joint products do not fully consider the irregularnature of building expansion joints. It is quite common for an expansionjoint to have several transition areas along its length. These may bewalls, parapets, columns or other obstructions. As such, the expansionjoint product, in some fashion or other, follows the joint. In manyproducts, this is a point of weakness, as the homogeneous nature of theproduct is interrupted. Methods of handling these transitions includestitching, gluing, and welding. All of these are weak spots from both awater proofing aspect and a fire resistance aspect.

SUMMARY OF THE INVENTION

As used herein, the term “waterproof” means that the flow of water isprevented, the term “water resistant” means that the flow of water isinhibited, and the term “fire resistant” means that the spread of fireis inhibited.

In one aspect, the present invention resides in a fire and waterresistant expansion and seismic joint system having a cover plate; aspline attached to the cover plate along a first edge of the spline; anda core comprising a first core portion and a second core portion, eachportion being located on an opposing face of the spline. The first coreportion and the second core portion have a fire-retardant materialinfused therein. The spline depends from the cover plate in a one piececonstruction and extends into the core to a depth within the core, andis positioned in a gap between substantially coplanar substrates suchthat the cover plate covers the gap. Each portion of the core iscompressed between a respective face of the spline and a face of one ofthe coplanar substrates.

In another aspect, the present invention resides in a fire and waterresistant expansion and seismic joint system having a cover plate; aspline attached to the cover plate along a first edge of the spline; anda core comprising a first core portion and a second core portion, eachportion being located on an opposing face of the spline. The first coreportion and the second core portion have a fire-retardant materialinfused therein. The spline depends from the cover plate in a one piececonstruction and extends into the core to a depth within the core. Thefirst core portion is compressed between the first face of the splineand one of the coplanar substrates and the second core portion iscompressed between the second face of the spline and the other of thecoplanar substrates. A layer comprising the fire retardant material issandwiched between the material of the core, and the core is not coatedwith any fire retardant material on any outer surface of the core.

In the expansion and seismic joint systems described herein, theelastomer material (if present) is cured and provides for watertightness (waterproofing and/or water resistance), the intumescentmaterial (if present) is cured to provide for fire resistance, and thefire retardant infused core provides for both fire resistance andmovement properties. These materials can, e.g., be assembled andarranged so as to offer water tightness in one direction and fireresistance in the other (an asymmetrical configuration), or in a fashionthat offers both water tightness and fire resistance in both directions(a symmetrical configuration) through a building joint. The system isdelivered to the job site in a pre-compressed state ready forinstallation into the joint.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of one embodiment of an expansion jointsystem of the present invention illustrating a multiple piece verticalelement or spline.

FIG. 1A is a schematic view of another embodiment of an expansion jointsystem illustrating a one piece vertical element or spline.

FIG. 2 is a schematic view of another embodiment of an expansion jointsystem of the present invention.

FIG. 3 is a schematic view of another embodiment of an expansion jointsystem of the present invention.

FIG. 4 is a schematic view of another embodiment of an expansion jointsystem of the present invention.

FIG. 5 is a schematic view of another embodiment of an expansion jointsystem of the present invention.

FIG. 6 is a schematic view of another embodiment of an expansion jointsystem of the present invention.

FIG. 7 is a schematic view of another embodiment of an expansion jointsystem of the present invention.

FIG. 8 is a schematic view of another embodiment of an expansion systemof the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The expansion joint systems described herein can be understood byreferring to the attached drawings and also to U.S. Pat. No. 6,532,708,which is incorporated by reference herein. One embodiment of anexpansion joint system as described herein is installed between concretesubstrates to define a concrete expansion joint system capable ofaccommodating movement of the concrete substrates due to thermal effectsand/or seismic effects. The present invention is not limited in thisregard, however, as the expansion joint system may be installed betweensubstrates or surfaces other than concrete. Materials for suchsubstrates or surfaces include, but are not limited to, glass, asphalt,stone (granite, marble, etc.), and the like. Furthermore, the expansionjoint systems described herein are generally referred to as beinghorizontally oriented; however, the present invention is not limited inthis regard, as the joint systems (with or without cover plates) canalso be installed vertically.

Referring to FIG. 1, one embodiment of an expansion joint system isshown at 10 and is hereinafter referred to as “system 10.” In system 10,a vertical element or spline 12 is located between horizontally-orientedconcrete substrates 50, two substrates 50A and 50B being shown. Thespline 12 can be positioned between concrete substrates 50 via the useof a cover plate 14 that is located over and spans a gap G between theconcrete substrates 50 such that the spline extends substantiallyvertically into the gap G. Fasteners 18 are used secure the cover plate14 to the spline 12.

The spline 12 can comprise one or more pieces. In a one-piece or“monolithic” configuration, the spline 12 comprises a suitable materialsuch as graphite or a plastic (e.g., polycarbonate, acrylic, polyvinylchloride, or the like) or any other material. While in some instances itis preferable that the spline material is non-electrically conductive,the present invention is not limited in this regard, as a monolithicspline 12 could be, e.g., metal or an alloy of two or more metals.

In a two-piece or multi-piece configuration, the spline 12 may comprisedifferent materials that are suitable for the application at hand, andthe materials may be metal and/or non-metal. For example, in anapplication where increased rigidity is desired, the spline 12 may becomprised of a first piece fabricated or formed from a metal and joinededge-to-edge with a second piece fabricated or formed from thenon-conductive material. Metals that may be used for the spline 12include, but are not limited to, aluminum, steel (e.g., stainlesssteel), and the like.

In one embodiment of a two-piece spline 12, shown in FIG. 1, an upperportion 15 includes holes 16, channels, or similar structure to receivethe fasteners 18. The upper portion 15 is an aluminum bar or rail havingholes 16 located in an upper end in which the fasteners 18 are received.A lower end of the upper portion 15 includes a protrusion 19 thatenables the upper portion to connect to a corresponding slot or the likein a lower portion 17 of the spline 12 in a dovetail-type fitting. Thepresent invention is not limited in this regard, as the upper portion 15can be connected to the lower portion 17 using any suitable means. Thelower portion 17 is preferably fabricated of the non-conductive plasticor similar material. A channel is located in a bottom end of the lowerportion, and an intumescent material 21 is located therein. The spline12 is not limited to the use of metal upper portions 15 andnon-conductive lower portions 17, as other materials are within thescope of the present invention.

FIG. 1A illustrates a non-limiting embodiment of a one piececonstruction of the vertical element or spline 12 where the upperportion 15 of the spline 12 extends to a depth D, as measured fromsubstantially a top surface of the core 22′ including any coating(s)thereon and extending vertically downward. It is noted that FIG. 1Aillustrates one non-limiting depth to which the spline 12 may extend andother depths are possible, according to embodiments. For instance,vertical element or spline 12 of FIG. 1A could extend all the way downto the lower edge 25 of core 22′ including any coating(s) thereon.Non-limiting examples of suitable depths to which the spline 12 couldextend, as measured from substantially the top surface 25A of the core22′ including any coating(s) thereon, to the lower edge 25 of core 22′including any coating(s) thereon (denoted by depth X) in FIG. 1A may becalculated as follows: D=0.25(X) (i.e., the suitable depth D of thevertical element or spline 12 extends 25% vertically down into the core22′ as measured from the top surface 25A including any coating(s)thereon), D=0.5(X), D=0.75(X), D=0.8(X), and so forth.

Whether the spline 12 is monolithic or constructed of multiple pieces,core 22′, including but not limited to, laminations of open celledpolyurethane foam 22 (hereinafter may be referred to as “foam 22” forease of reference which is not meant to limit the core 22′ to a foammaterial, but merely illustrate one exemplary material therefore) arearranged to form laminates 31, which are located on both sides of thespline 12 and are compressed in the gap G between the concretesubstrates 50, according to embodiments. The present invention is notlimited to the use of polyurethane foams, as other foams are within thescope of the present invention, and other non-foam materials also can beused for the core 22′, as explained below. The individual laminations31A are layers that extend parallel and in the direction in which thejoint extends and along the length thereof and are constructed byinfusing at least one, e.g., an inner lamination with an amount of fireretardant material 60. However, the structures of the present inventionare also not limited in this regard as, e.g., the foam 22 and/or core22′ may comprise a block of non-laminated foam or other material offixed size depending upon the desired joint size, a laminate comprisinglaminations oriented perpendicular to the direction in which the jointextends, or combinations of the foregoing.

Thus, foam 22 merely illustrates one suitable material for the core 22′.Accordingly, examples of materials for the core 22′ include, but are notlimited to, foam, e.g., polyurethane foam and/or polyether foam, and canbe of an open cell or dense, closed cell construction. Further examplesof materials for the core 22′ include paper based products, cardboard,metal, plastics, thermoplastics, dense closed cell foam includingpolyurethane and polyether open or closed cell foam, cross-linked foam,neoprene foam rubber, urethane, ethyl vinyl acetate (EVA), silicone, acore chemistry (e.g., foam chemistry) which inherently impartshydrophobic and/or fire resistant characteristics to the core; and/orcomposites. Combinations of any of the foregoing materials or othersuitable materials also can be employed. It is further noted that whilefoam 22 is primarily referred to herein for the core 22′, thedescriptions for foam 22 also apply to other materials for the core 22′,as explained above.

Because the amounts of foam 22 and/or core 22′ that are located oneither side of the spline 12 are substantially equal and subject tosubstantially the same environmental conditions, according toembodiments, the force of the compressed foam 22 and/or core 22′ as itexpands on one side of the spline 12 is substantially equal to the forceof the compressed foam 22 and/or core 22′ exerted on the other side ofthe spline, according to embodiments. Thus, once installed, the system10 is generally in equilibrium, and the spline 12 is self-centeringwithin the gap between the concrete substrates 50. The cover plate 14,which overlies the gap between the substrates 50 and generallycompletely covers the gap, is preferably centered with respect to thespline 12.

The core 22′ can be infused with a suitable material including, but notlimited to, an acrylic, such as a water-based acrylic chemistry, a wax,a fire retardant material, ultraviolet (UV) stabilizers, and/orpolymeric materials, combinations thereof, and so forth. A particularlysuitable embodiment is a core 22′ comprising an open celled foam infusedwith a water-based acrylic chemistry and/or a fire retardant material.

The core 22′ and/or at least one lamination of the foam 22/core 22′ maybe infused with a fire retardant material 60 to form the definedexpansion joint. The amount of fire retardant material 60 infused intothe core 22′, including, e.g., the open celled foam embodiment isbetween 3.5:1 and 4:1 in ratio with the un-infused foam/core itself byweight, according to embodiments. The resultant uncompressed foam/corewhether comprising a solid block or laminates, has a density of about130 kg/m³ to about 150 kg/m³ and preferably about 140 kg/m³. Othersuitable densities for the resultant core 22′ include between about 50kg/m³ and about 250 kg/m³, e.g., between about 100 kg/m³ and about 180kg/m³, and which are capable of providing desired water resistanceand/or water proofing characteristics to the structure.

One type of fire retardant material 60 that may be used is water-basedaluminum tri-hydrate (also known as aluminum tri-hydroxide (ATH)). Thepresent invention is not limited in this regard, however, as other fireretardant materials may be used. Such materials include, but are notlimited to, metal oxides and other metal hydroxides, aluminum oxides,antimony oxides and hydroxides, iron compounds, iron compounds such asferrocene, molybdenum trioxide, nitrogen-based compounds, phosphorousbased compounds, halogen based compounds, halogens, e.g., fluorine,chlorine, bromine, iodine, astatine, combinations of any of theforegoing materials, and other compounds capable of suppressingcombustion and smoke formation.

In the system 10, several laminations of the foam or other suitablematerial, the number depending on the desired size of the expansionjoint, are compiled and then compressed. For example, the spline 12 isplaced on an end surface of the compiled laminations, and severaladditional laminations are compiled and placed on the spline andcompressed. The entire core/spline/core (e.g., foam/spline/foam)assembly is held at compression in a suitable fixture. Similarly, a core22′ comprising laminations of non-foam material or comprising a solidblock of desired material may be compiled and then compressed and heldat such compression in a suitable fixture. The fixture is at a widthslightly greater than that which the expansion joint is anticipated toexperience at the largest possible movement of the adjacent concretesurfaces. At this width, the infused foam laminate or core 22′ is coatedwith a coating, such as a waterproof elastomer 24 at one surface (e.g.,on the top side), according to embodiments. This waterproof elastomermay be a polysulfide, silicone, acrylic, polyurethane, poly-epoxide,silyl-terminated polyether, a formulation of one or more of theforegoing materials with or without other elastomeric components orsimilar suitable elastomeric coating or liquid sealant materials, or amixture, blend, or other formulation of one or more of the foregoing.One preferred elastomer coating for application to a horizontal deckwhere vehicular traffic is expected is Pecora 301, which is a siliconepavement sealant available from Pecora Corporation of Harleysville, Pa.Another preferred elastomeric coating is Dow Corning 888, which is asilicone joint sealant available from Dow Corning Corporation ofMidland, Mich. Both of the foregoing elastomers are traffic grade ratedsealants. For vertically-oriented expansion joints, exemplary preferredelastomer coatings include Pecora 890, Dow Corning 790, and Dow Corning795.

Depending on the nature of the adhesive characteristics of the elastomer24, a primer may be applied to the outer surfaces of the laminations offoam 22 and/or core 22′ prior to the coating with the elastomer 24.Applying such a primer may facilitate the adhesion of the elastomer 24to the foam 22 and/or core 22′.

The elastomer 24 is tooled to create a “bellows” profile (or a similarprofile) such that the elastomeric material can be compressed in auniform and aesthetic fashion while being maintained in a virtuallytensionless environment.

The surface of the laminate 31 and/or core 22′ opposite the surfacecoated with the waterproofing elastomer 24 (the bottom side) is coatedwith an intumescent material 26, according to embodiments. One preferredintumescent material 26 is 3M CP25WB+, which is a fire barrier caulk.Both the coating of the elastomer 24 and the intumescent material 26 arecured in place on the foam 22 and/or core 22′ while the infused foamlamination/core is held at the prescribed compressed width. After theelastomer 24 and the intumescent material 26 have been cured, the entirecomposite and spline assembly is removed from the fixture, optionallycompressed to less than the nominal size of the material, and packagedfor shipment to the job site. This first embodiment is suited tohorizontal parking deck applications where waterproofing is desired onthe top side and fire resistance is desired from beneath.

In this system 10, a sealant band and/or corner bead 13 of the elastomer24 can be applied on the side(s) of the interface between the foamlaminate/core and the concrete substrate 50 to create a water tightseal. On the opposite side, a sealant band and/or corner bead 23 of theintumescent material 16 can be similarly applied to create a homogeneousintumescent face on the fire resistant side.

Referring now to FIG. 2, an alternate expansion joint system 110 of thepresent invention includes two portions of core 22′ and/or foam 22disposed on either side of the spline 12. The spline 12 may bemonolithic or constructed of multiple pieces. The core 22′ and/or foam22 has a first elastomer 24 coated on one surface (e.g., the top side)and the intumescent material 26 coated on an opposing surface (e.g., thebottom side). A second elastomer 25 is coated on the intumescentmaterial 26 and provides a waterproofing function. In this manner, thesystem 110 is water resistant in both directions and fire resistant inone direction. The system 110 is used in applications that are similarto the applications in which the system 10 is used, but may be usedwhere water is present on the underside of the expansion joint.Additionally, system 10 would be suitable for vertical expansion jointswhere waterproofing or water resistance is desirable in both directionswhile fire resistance is desired in only one direction. The secondelastomer 25 may also serve to aesthetically integrate the system 110with surrounding substrate material.

Sealant bands and/or corner beads 122 of the first elastomer 24 can beapplied to the sides as with the embodiment described above. On theopposite side, a band or bead of the intumescent material 26 can beapplied between the concrete substrate 50 and the foam lamination/corewith any excess being removed. Sealant bands and/or corner beads 124 canbe applied on top of the second elastomer 25, thereby creating a watertight seal between the concrete substrate 50 and the intumescentmaterial.

Referring now to FIG. 3, another expansion joint system of the presentinvention is shown at 210. In system 210, the core 22′ and/or foam 22 islocated on either side of the spline 12, which may be monolithic orconstructed of multiple pieces. The core 22′ and/or foam 22 is similarto or the same as the above-described foam, but both exposed surfaces(the top and bottom sides) are coated first with the intumescentmaterial 26 to define a first coating of the intumescent material on thetop side and a second coating of the intumescent material 26 on thebottom side. The first coating of the intumescent material 26 is coatedwith a first elastomer material 224, and the second coating of theintumescent material 26 is coated with a second elastomer material 225.This system 210 can be used in the same environments as theabove-described systems with the added benefit that it is bothwaterproof or at least water resistant and fire resistant in bothdirections through the joint. This makes it especially suitable forvertical joints in either interior or exterior applications.

In system 210, sealant bands and/or corner beads of the intumescentmaterial and sealant bands and/or corner beads 124 of the elastomer areapplied in a similar fashion as described above and on both sides of thefoam 22 and/or core 22′. This creates homogeneous intumescent layers anda water tight elastomer layer above them on both sides of the foam 22and/or core 22′ (on the top side and the bottom side).

Referring now to FIG. 4, another embodiment of the expansion jointsystem is shown at 310 and is hereinafter referred to as “system 310.”System 310 includes a spline 312 (similar to spline 5 of theaforementioned U.S. Pat. No. 6,532,708 (FIG. 4)), which is a monolithicelement having an I-shaped cross section defined by a vertical memberand two horizontally oriented flanges located at either end thereof.Spline 312 provides for both the cover plate anchor and theself-centering mechanism. The present invention is not limited in thisregard, however, as the spline 312 may be constructed of multiplepieces. Flanges 305 on the upper end of the spline 312 enable the coverplate 314 to be located on the spline and secured thereto using anysuitable fastener 18 (e.g., a screw). The vertical leg of the spline 312extends into the gap between the concrete substrates 50, and the lengththereof depends upon the joint dimensions and the size of the foam 22and/or core 22′ located on either side of the spline 312. The foam 22and/or core 22′ can be defined by any configuration of waterproofingelastomer, intumescent material, and beads as described above. Flanges315 located on the bottom end of the spline 312 support the foam 22and/or core 22′ and facilitate the retaining of the foam/core in thegap.

Referring now to FIG. 5, another embodiment of the expansion jointsystem is shown at 410 and is hereinafter referred to as “system 410.”System 410 compensates for irregularities in joint construction withregard to both horizontal and vertical joint parameters. In other words,the opposing sides of a joint may not be parallel or equidistant fromeach other. In such a case, the expansion of the foam 22 and/or core 22′incorporated into the joint on one side of the spline 412 may notreflect the same expansion characteristics of the foam on the other sideof the spline due to irregularities in width of the gap and/orvertical/horizontal alignment of concrete substrates 50.

In system 410, the spline 412 (which is similar to spline of theaforementioned U.S. Pat. No. 6,532,708 (FIG. 5) comprises two verticalelements positioned back-to-back, each including a top flange 405 and abottom flange 415. The top flanges 405 are each connected to the coverplate 14 via fasteners 18. The bottom flanges 415 facilitate the supportof the foam 22 against the respective vertical element of the spline 412and the concrete substrate 50. Each top flange 405 can be individuallytensioned to the cover plate 14 to allow the portions of foam 22 and/orcore 22′ on either side of the spline 412 to be adjusted independentlyso as to enable the foam to rest in the joint in the desired manner.Again, the foam 22 and/or core 22′ can be defined by any configurationof waterproofing elastomer, intumescent material, and beads as describedabove.

A system 510 as shown in FIG. 6 comprises a means to adjust the finalposition of the cover plate 14 relative to vertical elements of a spline512 (which is similar to spline of the aforementioned U.S. Pat. No.6,532,708 (FIG. 6)). The means to adjust the cover plate 14 is below thecover plate and comprises a bolt 519 or similar mechanism that extendslaterally through both vertical elements of the spline 512 and alsothrough vertical portions of angulated flanges 520 attached to upperends of the spline. Horizontal portions of the angulated flanges 520 arein turn attached to the cover plate 14 using fasteners 18. The angulatedportions 520 are adjustable relative to the vertical portions of thespline 512 by means of vertically-extending slots in the verticalportions and/or the angulated portions themselves, through which thebolt 519 extends, thus allowing each angulated portion to be adjustedand secured to accommodate the foam 22 and/or core 22′ and the coverplate 14 to suitably retain the foam 22 and/or core 22′. The foam 22and/or core 22′ is not shown in system 510, but it can be defined by anyconfiguration of waterproofing elastomer, intumescent material, andbeads as described above.

Referring now to FIG. 7, shown therein is another expansion joint system10 similar in some respects to the expansion joint system shown in FIG.1A and described above. Accordingly, like reference numbers refer tolike elements. In system 10 of FIG. 7, the core 22′ is infused with afire retardant material, as described above. As an example, the fireretardant material can form a “sandwich type” construction wherein thefire retardant material forms a layer 13′, as shown in FIG. 7, betweenthe material of the core 22′. Thus, the layer 13′ comprising a fireretardant can be located within the body of the core 22′ as, e.g., aninner layer, or lamination infused with a higher ratio or density offire retardant than the core 22′. It is noted that the term “infusedwith” as used throughout the descriptions herein is meant to be broadlyinterpreted to refer to “includes” or “including.” Thus, for example, a“core infused with a fire retardant” covers a “core including a fireretardant” in any form and amount, such as a layer, and so forth.Accordingly, as used herein, the term “infused with” would also include,but not be limited to, more particular embodiments such as “permeated”or “filled with” and so forth.

Moreover, it is noted that layer 13′ is not limited to the exactlocation within the core 22′ shown in FIG. 7 as the layer 13′ may beincluded at various depths in the core 22′ as desired. Moreover, it isfurther noted that this layer 13′ may extend in any direction. Forexample, layer 13′ may be oriented parallel to the direction in whichthe joint extends, perpendicular to the direction in which the jointextends or combinations of the foregoing. Layer 13′ can function as afire retardant barrier layer within the body of the core 22′.Accordingly, layer 13′ can comprise any suitable material providing,e.g., fire barrier properties. No coatings are shown on the outersurfaces of core 22′ of FIG. 7.

Accordingly, by tailoring the density as described above to achieve thedesired water resistance and/or water proofing properties of thestructure, combined with the infused fire retardant in layer 13′ orinfused within the core 22′ in any other desired foam including anon-layered form, additional layers, e.g., an additional water and/orfire resistant layer on either surface or both outer surfaces of thecore 22′ are not necessary to achieve a dual functioning water and fireresistant expansion and seismic joint system, according to embodiments.

It is noted, however, that additional layers could be employed ifdesired in the embodiment of FIG. 7, as well as in the other embodimentsdisclosed herein, and in any suitable combination and order. Forexample, the layering described above with respect to any/all of FIGS.1-6 could be employed in the embodiment of FIG. 7 and/or FIG. 8described below.

As a further example, FIG. 8 illustrates therein another system 10comprising the layer 13′ comprising a fire retardant within the body ofthe core 22′ as described above with respect to FIG. 7, and alsocomprising an additional coating 17′ on a surface of the core 22′.Coating 17′ can comprise any suitable coating, such as the elastomer 24described above, a fire barrier material including an intumescentmaterial described above or other suitable fire barrier material, e.g.,a sealant, a fabric, a blanket, a foil, a tape, e.g., an intumescenttape, a mesh, a glass, e.g., fiberglass; and combinations thereof.

Moreover, embodiments include various combinations of layering and fireretardant infusion (in layer and non-layer form) to achieve, e.g., adual functional water and fire resistant expansion and seismic jointsystems described herein. For example, FIG. 8, illustrates coating 17′on one surface of the core 22′ and a dual coating 18′ on the oppositesurface of the core 22′. The dual coating 18′ can comprise, e.g., aninner layer of elastomer 24, as described above, with an outer layer ofa fire barrier material including, e.g., an intumescent material.Similarly, the layers of dual coating 18′ can be reversed to comprise aninner layer of fire barrier material, and an outer layer of elastomer24.

Alternatively, only one layer may be present on either surface of core22′, such as one layer of a fire barrier material, e.g., sealant, on asurface of the core 22′, which is infused with a fire retardant materialin layer 13′ or infused in a non-layer form. Still further, othercombinations of suitable layering include, e.g., dual coating 18′ onboth surfaces of the core 22′ and in any combination of inner and outerlayers, as described above.

It is additionally noted that the embodiments shown in FIGS. 7 and 8 canbe similarly constructed, as described above with respect to, e.g.,FIGS. 1-3, modified as appropriate for inclusion/deletion of variouslayering and so forth. Thus, for example, as described above, while a“bellows” constructions is illustrated by some of the figures set forthherein, the embodiments described herein are not limited to such aprofile as other suitable profiles may be employed, such as straight,curved, and so forth.

Accordingly, as further evident from the foregoing, embodiments of thedual functioning water and fire resistant expansion and seismic jointsystems can comprise various ordering and layering of materials on theouter surface of the core 22′. Similarly, a fire retardant material canbe infused into the core 22′ in various forms to crate, e.g., a layered“sandwich type” construction with use of layer 13′.

Similarly, the variations described above can apply to both theafore-described one-piece, as well as multiple piece spline 12.

In each of the embodiments described herein, the infused foam laminateand/or core 22′ may be constructed in a manner such that the density offire retardant is consistent in the foam 22 and/or core 22′ regardlessof the final size of the product, according to embodiments. The startingdensity of the infused foam/core is approximately 140 kg/m³, accordingto embodiments. Other densities includes between about 80 kg/m³ andabout 180 kg/m³. After compression, the infused foam/core density is inthe range of about 160-800 kg/m³, according to embodiments. Afterinstallation the laminate and/or core 22′ will typically cycle betweendensities of approximately 750 kg/m³ at the smallest size of theexpansion joint to approximately 360-450 kg/m³, e.g., approximately400-450 kg/m³ (or less) at the maximum size of the joint. A density of400-450 kg/m³ was determined through experimentation, as a reasonablevalue which still affords adequate fire retardant capacity, such thatthe resultant foam can pass the UL 2079 test program. The presentinvention is not limited to cycling in the foregoing ranges, however,and the foam/core may attain densities outside of the herein-describedranges.

In expansion joint systems employing any of the systems as describedherein, installation is accomplished by adhering the foam laminateand/or core 22′ to the concrete substrate 50 using an adhesive such asepoxy, according to embodiments. The epoxy or other adhesive is appliedto the faces of the expansion joint prior to removing thecore/spline/core (e.g., foam/spline/foam) assembly from the packagingthereof (such packaging may comprise restraining elements, straps, ties,bands, shrink wrap plastic, or the like). Once the packaging has beenremoved, the foam laminate and/or core 22′ will begin to expand, and itshould be inserted into the joint in the desired orientation. Once thefoam lamination and/or core 22′ has expanded to suit the expansionjoint, it will become locked in by the combination of the foam 22 and/orcore 22′ back pressure and the adhesive. If a cover plate is installed,the cover plate can further facilitate the retention of the foamlamination in place in the joint.

In vertical expansion joint systems employing any of the systems asdescribed herein, an adhesive may be pre-applied to the core/spline/core(e.g., foam/spline/foam) assembly. In this case, for installation, theassembled foam laminate/core and spline with the pre-applied adhesive isremoved from the packaging and inserted into the space between theconcrete surfaces to be joined where it is allowed to expand to meet theconcrete substrate. Once this is done, the adhesive in combination withthe back pressure of the foam 22 and/or core 22′ will hold the foam 22and/or core 22′ in position. The cover plate can then be attached to thespline 12.

To fill an entire expansion joint, the installation as described aboveis repeated as needed. To join the end of one foam laminate and/or core22′ to the end of another in either the horizontal configuration or thevertical configuration, a technique similar to that used with thesealant band and/or corner beads can be employed. After inserting onesection of a system (joint) and adhering it securely to the concretesubstrate, the next section is readied by placing it in proximity to thefirst section. A band or bead of the intumescent material and theelastomer material is applied on the end of the foam laminate in theappropriate locations. The next section is removed from the packagingand allowed to expand in close proximity to the previously installedsection. When the expansion has taken place and the section is beginningto adhere to the substrates (joint faces), the section is firmly seatedagainst the previously installed section. The outside faces are thentooled to create an aesthetically pleasing seamless interface.

The above mentioned installation procedure is simple, rapid, and has noinvasive elements which impinge upon or penetrate the concrete (orother) substrates. This avoids many of the long term problems associatedwith invasive anchoring of screws into expansion joint faces.

It is further noted that the various embodiments, includingconstructions, layering and so forth described herein, can be combinedin any combination and in any order. Thus, the embodiments describedherein are not limited to the specific construction of the figures, asthe various materials, layering and so forth described herein can becombined in any desired combination and order.

Although this invention has been shown and described with respect to thedetailed embodiments thereof, it will be understood by those of skill inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of theinvention. In addition, modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodimentsdisclosed in the above detailed description, but that the invention willinclude all embodiments falling within the scope of the appended claims.

What is claimed is:
 1. A fire and water resistant expansion and seismicjoint system, comprising: a cover plate; a spline attached to the coverplate; a core having a fire retardant material infused therein locatedon a first face and a second face of the spline; wherein the splinedepends from the cover plate and is configured to be positioned in a gapbetween substrates such that the cover plate overlies the gap; andwherein the core is compressible between the first face of the splineand one of the substrates and is compressible between the second face ofthe spline and the other of the substrates, and wherein the fireretardant infused core has a density when compressed of about 160 kg/m³to about 800 kg/m³, and the fire and water resistant expansion andseismic joint system and the fire retardant infused core are capable ofwithstanding exposure to a temperature of about 540° C. at about fiveminutes, and the fire retardant infused core is configured to passtesting mandated by UL
 2079. 2. The fire and water resistant expansionand seismic joint system of claim 1, wherein a ratio of fire retardantmaterial infused into the core is in a range of about 3.5:1 to about 4:1by weight.
 3. The fire and water resistant expansion and seismic jointsystem of claim 1, wherein the fire retardant material infused into thecore is selected from the group consisting of water-based aluminumtri-hydrate, metal oxides, metal hydroxides, aluminum oxides, antimonyoxides and hydroxides, iron compounds, ferrocene, molybdenum trioxide,nitrogen-based compounds, phosphorus based compounds, halogen basedcompounds, halogens, and combinations of the foregoing materials.
 4. Thefire and water resistant expansion and seismic joint system of claim 1,comprising a fire barrier sealant layer.
 5. The fire and water resistantexpansion and seismic joint system of claim 1, comprising a waterresistant layer on the core.
 6. The fire and water resistant expansionand seismic joint system of claim 1, wherein the fire and waterresistant expansion and seismic joint system and the fire retardantinfused core is capable of withstanding exposure to a temperature ofabout 930° C. at about one hour to pass the UL 2079 testing.
 7. The fireand water resistant expansion and seismic joint system of claim 1,wherein the fire and water resistant expansion and seismic joint systemand the fire retardant infused core is capable of withstanding exposureto a temperature of about 1010° C. at about two hours to pass the UL2079 testing.
 8. The fire and water resistant expansion and seismicjoint system of claim 1, wherein the fire and water resistant expansionand seismic joint system and the fire retardant infused core is capableof withstanding exposure to a temperature of about 1260° C. at abouteight hours to pass the UL 2079 testing.
 9. The fire and water resistantexpansion and seismic joint system of claim 1, wherein the fire andwater resistant expansion and seismic joint system and the fireretardant infused core are capable of withstanding exposure to atemperature of about 1052° C. at about three hours to pass the UL 2079testing.
 10. The fire and water resistant expansion and seismic jointsystem of claim 1, wherein the fire and water resistant expansion andseismic joint system and the fire retardant infused core are capable ofwithstanding exposure to a temperature of about 1093° C. at about fourhours to pass the UL 2079 testing.
 11. The fire and water resistantexpansion and seismic joint system of claim 1, wherein a layercomprising the fire retardant material is sandwiched between material ofthe core.
 12. The fire and water resistant expansion and seismic jointsystem of claim 11, wherein the layer is oriented, with respect to adirection in which the joint extends in its width, in at least one of aparallel orientation, a perpendicular orientation, and a combinationthereof.
 13. A fire and water resistant expansion and seismic jointsystem, comprising: a cover plate; a spline attached to the cover plate;a core having a fire retardant material included therein located on afirst face and a second face of the spline; wherein the spline dependsfrom the cover plate and is configured to be positioned in a gap betweensubstrates such that the cover plate overlies the gap; and wherein thecore is compressible between the first face of the spline and one of thesubstrates and is compressible between the second face of the spline andthe other of the substrates, and wherein the core having the fireretardant material included therein has a density when compressed ofabout 160 kg/m³ to about 800 kg/m³, and the fire and water resistantexpansion and seismic joint system is configured to maintain fireresistance upon exposure to a temperature of about 540° C. at about fiveminutes, and the core having the fire retardant included therein isconfigured to pass testing mandated by UL
 2079. 14. The fire and waterresistant expansion and seismic joint system of claim 13, wherein thecore with the fire retardant material has a density when compressed in arange of about 200 kg/m³ to about 700 kg/m³.
 15. The fire and waterresistant expansion and seismic joint system of claim 13, wherein thecore with the fire retardant material uncompressed has a density ofabout 130 kg/m³ to about 150 kg/m³.
 16. The fire and water resistantexpansion and seismic joint system of claim 13, wherein the core withthe fire retardant material compressed has a density in a range of about400 kg/m³ to about 450 kg/m³.
 17. The fire and water resistant expansionand seismic joint system of claim 13, wherein the system is configuredto maintain fire resistance upon exposure to a temperature of about 930°C. at about one hour to pass the UL 2079 testing.
 18. The fire and waterresistant expansion and seismic joint system of claim 13, wherein thesystem is configured to maintain fire resistance upon exposure to atemperature of about 1010° C. at about two hours to pass the UL 2079testing.
 19. The fire and water resistant expansion and seismic jointsystem of claim 13, wherein the core comprises at least one ofpolyurethane foam, polyether foam, open cell foam, dense closed cellfoam, cross-linked foam, neoprene foam rubber, urethane, cardboard, anda composite.
 20. The fire and water resistant expansion and seismicjoint system of claim 13, wherein a layer comprising the fire retardantmaterial is sandwiched between material of the core, and the core is notcoated with any fire retardant material on any outer surface of thecore, and the fire and water resistant expansion and seismic jointsystem is configured to maintain fire resistance upon exposure to atemperature of about 540° C. at about five minutes to pass the UL 2079testing.
 21. The fire and water resistant expansion and seismic jointsystem of claim 13, wherein the system is configured to maintain fireresistance upon exposure to a temperature of about 1052° C. at aboutthree hours to pass the UL 2079 testing.
 22. The fire and waterresistant expansion and seismic joint system of claim 13, wherein thesystem is configured to maintain fire resistance upon exposure to atemperature of about 1093° C. at about four hours to pass the UL 2079testing.
 23. A fire and water resistant expansion and seismic jointsystem, comprising: a cover plate; a spline attached to the cover plate;a core having a fire retardant material permeated therein located on afirst face and a second face of the spline; wherein the spline dependsfrom the cover plate and is configured to be positioned in a gap betweensubstrates such that the cover plate overlies the gap; and wherein thecore is compressible between the first face of the spline and one of thesubstrates and is compressible between the second face of the spline andthe other of the substrates, and wherein the core having the fireretardant permeated therein has a density when compressed of about 160kg/m³ to about 800 kg/m³, and the fire and water resistant expansion andseismic joint system is configured to maintain fire resistance uponexposure to a temperature of about 540° C. at about five minutes, andthe core having the fire retardant permeated therein is configured topass testing mandated by UL
 2079. 24. The fire and water resistantexpansion and seismic joint system of claim 23, wherein the system isconfigured to maintain fire resistance upon exposure to a temperature ofabout 930° C. at about one hour to pass the UL 2079 testing.
 25. Thefire and water resistant expansion and seismic joint system of claim 23,wherein the system is configured to maintain fire resistance uponexposure to a temperature of about 1010° C. at about two hours to passthe UL 2079 testing.
 26. The fire and water resistant expansion andseismic joint system of claim 23, wherein the system is configured tomaintain fire resistance upon exposure to a temperature of about 1052°C. at about three hours to pass the UL 2079 testing.
 27. The fire andwater resistant expansion and seismic joint system of claim 23, whereinthe system is configured to maintain fire resistance upon exposure to atemperature of about 1093° C. at about four hours to pass the UL 2079testing.
 28. The fire and water resistant expansion and seismic jointsystem of claim 23, further including a layer comprising the fireretardant material is sandwiched between material of the core.
 29. Thefire and water resistant expansion and seismic joint system of claim 28,wherein the layer is oriented, with respect to a direction in which thejoint extends in its width, in at least one of a parallel orientation, aperpendicular orientation, and a combination thereof.